Process Engineering Exam

Pregunta	Respuesta
What do you understand by plant?	A plant is a system for the realization of a physical, chemical or biological process. The aim of the process is to convert raw materials into a desired product. The plant consists of equipment, piping and instrumentation
What do you understand by equipment?	Equipment means reactors, columns, heat exchangers and so on. The main equipment of a plant is often a reactor. In the reactor, chemical or biological reactions are performed. In order to get a high yield and selectivity, the process variables such as temperature, pH-value or medium composition have to be maintained at an optimum level
What are the objectives of the following company: Engineering company Give an example	Objective: Design and construction of process plants (turn key plants) Examples: Jacobs Engineering, Pasadena, California LSMW, Stuttgart, Germany
What are the objectives of the following company: Equipment manufacturers Give an example	Objective: Development and manufacturing of equipment Examples: Sartorius Stedim Bioengineering GE Healthcare
What are the objectives of the following company: Chemical or pharmaceutical companies Give an example	Objective: Development and manufacturing of chemical and pharmaceutical products Examples: BASF Roche Nestle
What do you understand by feasibility study?	A feasibility study is a preliminary study undertaken to evaluate a project's viability. The term feasibility study can also refer to the resulting document. The outcome of the feasibility study is used to make a decision whether to proceed with the project, or drop it.
What information is provided by the market analysis?	Market volume Market share Market growth Market price
Name three methods which are used for a market analysis?	Utilization of market studies Statistical year books Customer interviews
Cost correlation	C=cx1^(m1) C=cx1^(m1)*x2^(m2) C=Equipment cost x1,x2=capacity parameter c,m1,m2=constant
2.3 Degression exponent	C=C0*(x/x0)^m C=Eq. cost C0=Eq. cost of base size x=capacity parameter x0=cap. param. of basic size m=degression exponent
2.4 Cost indexes	C=C0*(I/I0) C=cost of eq. at present time C0=cost of eq. at previous time I=cost index at present time I0=cost index at previous time
2.5 Factored estimate procedure	Cp=Ceq*f Cp=total plant cost Ceq=total costs of major equipment f=multiplication factor
Name the two methods used to estimate the profitability. When are they applied?	Cost comparison, is applied to evaluate different alternatives for the same objective or to check if a modification is economical Profitability is used to evaluate whether its economical to build or operate a plant Profitability=(Profit/capital)100% P=(S-C)/(Cp+Cw)100%
What is the objective of process development?	The objective of process development is to establish a process to produce a desired product in an industrial scale taking into account economic, ecological and safety boundary conditions.
What are the two objectives of product characterization?	Identification of the product characterization of the product The identification of the product is like a fingerprint of the product and can be used later on to clarify the reasons for problems during comiss. and operation of the plant
Name five types of product properties	Biological properties Chemical properties Mechanical properties Thermal properties Safety properties Toxicity properties
What two decisions are influenced by the product behavior?	Product properties -> Behavior Equipment selection Operating conditions
What is the objective of equipment selection?	The objective of equipment selection is to choose the most suitable equipment for an individual unit operation
Name the essential criteria for equipment selection	Operating data Product data Equipment data Material data Laws and regulations
Name three methods for equipment selection	Experience Decision trees Decision charts Expert systems
What are the two objectives for equipment design?	Determination of the equipment size Determination of the operating conditions
Name the essential criteria for equipment design?	Operating data Product data Equipment data
Name the to methods for equipment design?	Approximate design early in proc.dev., quick to make, limited data needed Detailed design advanced stage in p.d., based on models, made on computers reliable data needed
What is the objective of conceptual design?	The objective of conceptual design is to develop a concept for the plant to be built. Potential solutions e.g. alternative sites for the plant are evaluated and a specification for the plant is developed. Provides the basis for the basic design
Name three documents produced throughout conceptual design?	Block flow diagram Functional layout Personnel and material flow Process simulation Cost estimation
What is a block flow diagram?	BFDs are used for illustrating a process or plant in a simple form. They consist of rectangular blocks connected by lines. Blocks represent process steps, lines represent material and energy flows
Drawing of a simple Block Flow Diagram	Image: Bfd (image/gif)
What is the objective of basic design?	Objective is development of a basic design for the plant to be built. It's based on conceptual design, focuses on type and dimensions of major equipment, design temperatures, pressures, materials. Establishment of plant layout
Name three documents produced throughout basic design	Process flow diagram Equipment list Process data sheets Plant layout Utilities distribution scheme Electrical equipment list Soil report
What is a process flow diagram? (What is it used for? What does it consist of?)	PFDs are used for illustrating a process in more detail. It consists of standardized symbols which are connected by lines. Symbols represent major eq. (reactor, pump, heat exch.) Lines represent material and energy flow.
What document is used for the specification of equipment?	Process data sheets The size of equipment depends on flow rates or amounts of material or energy to be handled. These design data are entered in process data sheets, which contain all relevant specifications for the equipment
What is the objective of detail design?	In detail design the project team prepares detailed flow sheets, equipment drawings, eq. data sheets, piping drawings, piping specifications and layouts so actual production step can begin
Name three documents produced throughout detail design?	Piping and Instrumentation Diagram Piping specification Final plant layout Detailed flow sheets Detailed eq. data sheets
What is a piping and instrumentation diagram? (What is it used for? What does it consist of?)	P&ID is based on PFD. It represents the technical realization of a process. It consists of graphical symbols for eq. and piping together with graphical symbols for measurement and control functions
Meaning of letter codes for instrument functions: TI PDI TIC PDIC	Temperature Indication Pressure Difference Indication Temperature Indication Controlling Pressure Difference Indication Controlling
What type of drawing is used to depict pipe runs?	Piping drawing that show both the geometry of the run and its location in the plant. Diagram with a single pipe run and its components, along with measurement and control devices and piping supports.
What are the four main tasks of a project manager throughout project execution?	Establishment of project organization Coordination of subtasks Direction if subtasks Monitoring and control of subtasks
Describe a structural organization	The structural organization illustrates the departments and teams of a company and the relationships between them. Image: Structural (binary/octet-stream)
Describe process organization	The proc.org. illustrates the work flow of a business process. The work flow consist of an input, activities and an output Image: Processorga (binary/octet-stream)
Explain the three types of structural organizations	Functional organization: structured according to functions, well suited for companies with a single or dominant core product Divisional organization: number of self-managed divisions, each operates as a profit center (business units). Based on product or market. Centrally provided financing and HR. Matrix organization: Overlay of the two previous, combines product with geographical. Employees have two bosses.
What two types of project organizations can be distinguished?	First for large projects (PO1) Project manager with executive authority. P members are exclusively assigned to the P team for the duration of the P. P members report to PM Second for smaller projects(PO2). P members are not exclusive to the P team. PM has dotted line authority. P members report to their department M.
Name three consequences of delays	Req. of additional personal resources Incurring of additional costs Payment of penalties Claim to consequential damages Loss of reputation
What is a network diagram?	Illustration of a complex project in form of a netwrok(arrows and nodes), which can be used for a structural nalysis and optimization of the work flow
What are the two phases in network planning?	Planning phase: breakdown of the overall project into smaller activities and definition of the dependencies between activities Scheduling phase: Estimation of the durations and finish dates for overall activities
Three most important network diagram methods?	CPM Critical path method (activity on arrow) MPM Meta potential method (activity on node) PERT Program evaluation and review technique (event on node method)
What are the two main consequences of cost overruns?	Reduction of profit of engineering company building the plant Reduction of profit of manufacturing company operating the plant Procurement has a key role in lowering costs.
Two methods of cost control	Cost tables for the manufacturing and installation of eq. Cost diagrams
Three types of documentation for the plant	Execution (for technical and commercial execution) Technical (about design and function of indiv. eq. and total plant) Operating (docs about operation of indiv. eq. and total plant)
What is the objective of construction?	The objective of construction is to build a plant. It includes all activities from excavation to mechanical completion
What are the main tasks during construction of a plant?	Procurement of eq., materials, services Construction of the building Erection and installation of eq. Installation of electrical system, measuring and control equiment Functional test of equipment
Main tasks of procurement?	Purchase of equipment, materials, services Expediting during fabrication of eq. (Cost Time Quality) Shipping of eq. and materials to construction site
What are the three basic types of shipping?	Land, Sea and Air. Land- Trucks, Train- versatile Sea still requires land transport (harbor)- cheap Air also requires Land transport (Airport)-quick
Mechanical completion	When functional tests have been successful, mechanical completion is achieved. Generally, a plant is mechanically completed when subsequent commissioning will not be delayed or disrupted by installation work and that the safety of the plant is guaranteed.
What is the objective of commissioning?	To assure the proper function of the plant and that the contractual guarantees are achieved. It includes all activities from mechanical completion until hand over of the plant.
Main tasks during commissioning of a plant?	Test run of eq. with water (cold comiss.) Test run with product (warm comiss.) Test run complete plant Proof of compliance with guarantees Training personnel
What is a contract?	A legally binding exchange of promises or agreements between parties that will be enforced by law
What types of contracts can be distinguished according to contractual obligations?	Sales contract (Seller-Buyer) Rental or lease (Lessor - Lessee) Loan contract (Lender - Borrower) Employment contract (Employer-Employee) Work contract (Contractor-Buyer)
What types of contracts can be distinguished according to the scope of work?	Consulting contract Engineering contract Supply contract Construction contract Commissioning contract Service contract License contract
What types of contracts can be distinguished according to the mode of payment	Lumpsum contract Target cost contract Cost contract Measure and value contract
Elements of a contract	Names, addresses, roles of parties Preamble Deadlines Insurances Prices, terms of payment Warranties Penalties Duration of contract Termination of contract Confidentiality Signatures
What are the two possible conclusions of a contract	Contract signed by all parties (few disagreements) Offer-order-order confirmation (more disagreement)
Two kinds of warranties for a process plant	Process warranty : assurance of defined processes (Production capacity, Product quality, energy consumption) Mechanical warranty: Assurance of function of parts (excluding wear parts) during warranty period (limited usually 12 months max 18)
Name three elements which a notification of defects shall contain	Description of defect Request to remedy the defect Time limit for remedy of said defect
Three possibilities to protect an engineering company against inability of payment	Advance payment Letter of credit Export credit guarantee
How to avoid currency risk	Hedging currency risks (exchange rate guarantee)
What do you understand by quality assurance system	QAS cover all organisational and technical elements needed to achieve required quality Requirements for QAS are defined in standards like ISO 9000 - ISO 9004 Quality of product not only after production, but throughout entire production
Name five elements of a quality assurance system	Management responsibility Quality system Contract review Design Control Document control Product ID and Trace Process Control Inspection and testing Quality records Training
Extend these abbreviations: QMS QA QC SOP FDA EMEA	Quality management system Quality assurance Quality control Standard operating procedure Food and Drug Administration European Medicines Agency
Extend these abbreviations: GMP cGMP GAMP GLP GCP	Good Manufacturing Practice current Good Manufacturing Practice Good Automated Manufacturing Practice Good Laboratory Practice Good Clinical Practice
What do you understand by GMP	GMP is a term that is recognized worldwide for the management and control of manufacturing food and pharmaceutical products. It consists of a set of principles and regulations that are followed by manufacturers of food and pharma. products in order to ensure high quality
What do you understand by validation	Documented verification that a process, operated within the established parameters, is performing effectively and is reproducible in order to produce an intermediate or active pharma. ingredient meeting its predetermined specifications and quality attributes
What do you understand by qualification	Documented verification that an equipment or system is properly designed (DQ), properly installed (IQ), works correctly (OQ) and actually leads to the expected result (PQ)
What three types of validation can be distinguished according to the time of execution?	Prospective validation Concurrent validation Retrospective validation
Six steps of validation	Validation master plan (VMP) Risk analysis (RA) Design Qualification Installation Qualification Operation Qualification Performance Qualification
Extend thee abbreviations VMP RA DQ IQ OQ PQ	Validation Master Plan Risk Analysis Design Qualification Installation Qualification Operating Qualification Performance Qualification
What is a validation master plan?	The VMP provides the essential framework for performing the validation process it includes: Steps of validation Allocation of responsibilities Establishment of time-schedule Organisation of documentation
Objective of risk analysis	To identify critical process steps an parameters, and estimate their impact on product quality FMEA (failure mode and effect analysis) RPZ=AxBxE Risk priority number= likelihood of appearanceImportance of systemLikelihood of discovery
Objective of design qualification	Documented verification that the proposed design of an equipment or system is suitable for the intended purpose
Objective of Installation Qualification	Documented verification that the equipment or system, as installed or modified, complies with the approved design, the manufacturers recommendations and/or user requirements
objective of Operation Qualification	Documented verification that the equipment or system, as installed or modified, operates as intended throughout the anticipated operating ranges
Objective of Performance Qualification	Documented verification that the equipment and systems, as connected together, perform effectively and are reproducible, based on the approved process method and specifications

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	Creado por Márton András Nagy hace casi 7 años